9 - Chapter 5-MCE PDF

PdMA MCEGold PRODUCT SUPPORT MANUAL MCE
REV. 0-04/08 2008 PdMA Corporation 5-1

CHAPTER 5: MCE
TESTING QUICK START
MCE testing may be started by selecting either the Test Selection or the MCE Auto
icons on the toolbar.
Selecting the MCE Auto icon automatically runs the Standard Test followed by the
Polarization Index test. It uses the existing testing setup values. MCE Auto is discussed in
detail on page 5-7.
Selecting the Test Selection icon allows you to verify and/or change the testing setup
values and select which test you want to run. Test Selection is discussed in detail on page
5-3.
1. Start MCEGold.
2. On the Site Navigator or WatchList highlight the asset to be tested.
3. Select the Test Selection icon on the tool bar to open the Test Selection window.
4. In the Test Selection window the default is set to MCE testing. For EMAX testing click
the EMAX tab at the top and see Chapters 6 & 7. The asset section tabs along the left
side will vary depending on the type of asset being tested. Nameplate Information is
automatically filled in by MCEGold from the nameplate data.
5. Select the asset section tab along the left side corresponding to the section to be
tested.
6. Select the test to be performed from the list of tests. The available selections are
driven by the type of asset and the asset section selected for testing. The Notes section
provides instructions that are relevant for the selected test.
7. Select the asset test location by using the drop-down list or using the search button to
open the Test Location Selection window.
8. Select the Test Frequency from the drop-down list. The Test Frequency default is
driven by the type of asset selected for testing.
9. Select the Resistance-to-Ground by entering in the Mohms if they are different from
the default. Check the Low Limit check box if you want the unit to shut down
automatically upon measuring a specified low resistance to ground value.
10. Select the Voltage from the drop-down list box. The choices are: 250, 500, 1000,
2500, and 5000.
11. Set the asset Temperature if different from the default value of 40.
MCE PdMA MCEGold PRODUCT SUPPORT MANUAL
5-2 2008 PdMA Corporation REV. 0-04/08
12. Select the charge time from the drop-down list box. The choices are in 15 second
increments, beginning at 15 and ending at 600 seconds.
13. Click Save to save the MCE Test Setup values selected for this particular asset or
click Reset to restore the original values. Note: Original values may only be reset if
new values have not been saved. If you have clicked the Save button it will be
necessary to manually change them back to the originals and save them.
14. Click Test to go the test window.
15. Click Test on the Test window. From this point the process will differ depending on
the test being performed. Each test is covered in detail later in this chapter.
INTRODUCTION
The MCE tester measures natural characteristics of a deenergized asset and its circuit to
determine its condition. These characteristics are resistance-to-ground, capacitance-to-
ground, winding resistance, and winding inductance. MCE testing can identify faults in
the power circuit, insulation, stator, rotor, and the air gap between the rotor and stator.
The tests that can be run on a asset vary, depending on the asset type. For AC assets
(Induction, Synchronous, and Wound Rotor) the tests are AC Standard Test, Polarization
Index (PI) which includes a Dielectric Absorption Ratio, Rotor Influence Check (RIC),
and Step Voltage. For DC assets the tests are DC Standard Test, Polarization Index (PI)
which includes a Dielectric Absorption Ratio, Bar-to-Bar (Armature Circuit only), and
Step Voltage.
Both AC and DC assets have an MCE Auto test which runs the Standard test followed by
the Polarization Index test, automatically saves the test results, and displays the Fault
Zone Report at the end of testing.
The frequency and type of asset testing you perform is based on your experience with the
tester, the condition of each individual asset, and the criticality/application of each asset.
Since it may be impossible to test each and every asset in your facility, ask yourself the
following questions when deciding which assets to test.
Is the asset easily replaceable and if so, is a replacement readily available?
Would buying a new asset cost less than repairing the old asset?
Is the asset redundant or non-critical?
If you answered yes to all three of these questions, you may not want to consider this asset
for your monitoring program.
If you are unfamiliar with an asset, review its maintenance history of test results,
problems, and repairs before testing it. Talk with the operators who run it and anyone who
may have information about its repair history. This will give you a more complete picture
of the condition of the asset.
MCE test results give you a comprehensive picture of the electrical condition of the asset.
MCE results can be utilized, along with results obtained from other technologies, to get a
complete picture of the health of the asset. Some examples of other technologies include
vibration, oil analysis, and infrared thermography.
Some of the MCE tests give you enough information to call an asset good or bad, based on
results from one test. Other MCE tests give you data which is best used for trending and
comparison.
Trending means comparing sequential test results for the same asset over time. This tracks
what the particular asset is doing, how it is holding up, when it may need to be cleaned,
when it needs more detailed maintenance, or when a fault develops.
Test frequency depends on the assets criticality and the condition of the asset when it is
first tested. As the asset ages, you may decide to test it more frequently to better track its
condition.
When you first start testing with the MCE, the initial test is automatically designated as
the baseline test. After maintenance is performed on an asset and it is returned to optimal
condition, measure subsequent tests against that condition by designating the first test
after the maintenance as the new baseline.
Comparison means comparing individual test results on one asset with test results from an
identical asset operating in a similar environment. By identical asset we mean the same
manufacturer, voltage and horsepower rating, cable length for MCC, etc. For example, if
there are four like assets operating side by side performing the same task, all running at
approximately the same load, each running about the same amount of time, the test data
should be very close for all of them. If all four assets are tested, and three are basically the
same, but the fourth is very different from the other three, look for potential problems with
the fourth asset.
MCE testing is performed on a deenergized asset. However, there may be energized
circuitry in the same cabinet in which you connect the tester.
FOLLOW ALL ELECTRICAL SAFETY PRECAUTIONS AND PROCEDURES
FOR WORKING IN THE VICINITY OF ENERGIZED EQUIPMENT. READ THE
ELECTRICAL SAFETY PRECAUTIONS IN CHAPTER ONE BEFORE
PERFORMING ANY TESTS.
For AC assets, test lead colors of black, blue, and red connect to phases 1, 2, and 3 (left to
right, top to bottom); green connects to ground. For DC assets, test lead colors of black
and blue connect to F1/A1 and F2/A2; the red lead is not used; green connects to ground.
The DC Bar-to-Bar pistol grip or pencil probe test leads connect to commutator bars.
Some asset circuits may have surge capacitors and/or power factor correction capacitors
installed. It is important to know about them since these components affect the values of
the collected data and increase the time and number of steps involved in troubleshooting.
Testing can be performed with the power or surge capacitors installed, however, surge
capacitors must be removed for the accurate measurement of the assets insulation
resistance-to-ground. If an asset appears faulty with the power factor capacitors installed,
disconnect them and perform the testing again to isolate the fault.
TEST SELECTION WINDOW
In this chapter, the MCE aspects of asset testing are discussed. EMAX testing is discussed
in the Power and Current Analysis chapters. The Test Selection window discussion is
followed by the Step-by-step testing procedures, Test Data Analysis on page 5-53, and
finally MCE Analysis on page 5-74.
Note: Selecting the MCE Auto test icon on the tool bar bypasses the Test Selection
window and automatically runs the Standard Test followed by the Polarization Index test
using either the default or previously saved test settings, at the end of testing the test
results are saved, and the Fault Zone Report opens.
To open the Test Selection Window click the Test Selection icon on the tool bar.
The Test Selection window is shown in Figure 5-1. The asset name is located on the title
bar to the right of the window name. The Test Selection window is used for both MCE and
EMAX testing by selecting the desired test type tab.
The asset section tabs are found along the left side of the test selection area and are
dependent on the asset type. Possible sections are Armature Circuit, Field Circuit, Resistor
Bank, Rotor, and Stator.
For AC Induction assets, the only option is Stator.
For AC Synchronous assets, options are Field Circuit and Stator.
For Wound Rotor assets, options are Stator, Rotor, and Resistor Bank.
For DC assets, options are Armature and Field Circuit.
Figure 5-1: Test Selection Window
Test List
The top left section of the window contains a list of test selections for either MCE or
EMAX, depending on asset type, test type and asset section tabs selected. The test lists
section displays the various tests which may be performed based on the asset type and
asset section chosen. When a test is selected, the name of the test is highlighted blue and
the test set up area changes to values appropriate for the test selected. The test list
possibilities for MCE testing are:
MCE Auto
Standard (AC asset)
Standard (DC asset)
Polarization Index
Rotor Influence Check (RIC)
Step Voltage
Synchronous (Synchronous, Field section)
Resistor Bank (Wound Rotor, Resistor Bank section)
Commutator Bar-to-Bar (DC asset)
Asset Information
Asset Information is located on the right side. This area displays the Condition Code and
nameplate information of the asset being tested. The information comes from the
nameplate data that was entered when the asset was set up and cannot be edited on this
window. Information displayed, depending on asset type, may include: Type, Frame #, NP
Frequency, Voltage, FLA, HP, PF, Eff, Speed, Slots, and Bars. Also, Field Volts and Field
Current are listed for DC assets.
MCE Test Setup
The lower half of the Test Selection window is devoted to test set-up selections. The set-
up options depend on the asset type and test selected.
Asset Test Location
The Asset Test Location default is Not Assigned. To assign a test location, click the down
arrow and select from the list. If the location is not known, click the browse button .
The Test Location Selection window opens displaying a test location graph for the type of
asset selected. See Figure 5-2. Use the graph to determine the location, then click the
down arrow in the Test Location text box, select the location from the list, and click OK.
Figure 5-2: AC Asset Test Location
Test Frequency
Test Frequency is selected from a drop-down box. Click the down arrow and select from
the list to change the frequency. The choices are 300 or 1200 Hz depending on the section
being tested. Test Frequency is not available for the resistor bank section of a wound rotor
asset.
Resistance-to-Ground
Resistance-to-Ground provides the option to check (turn on) the Low Limit Shut Off and
enter a shut off voltage.
Voltage
Voltage is selected from a drop-down list. Click the down arrow and select from the list to
change the voltage. The voltage choices are from 250, 500, 1,000, 2,500, and 5,000.
Select a voltage of 500 or 1000 volts, based on the assets voltage. EASA (Electrical
Apparatus Service Association), in their booklet How to Get the Most From Your Electric
Motors, suggests 500 volts for assets rated <2400 volts and 1000 volts for assets rated at
>2400 volts.
Asset Temperature
The default value is 40 C. The value may be changed by typing in a new value.
Span
Span selection is only available for Bar-to-Bar testing of the armature section of DC
assets.
Charge Time
Charge time is available for the Standard test of an AC Induction, Wound Rotor,
Synchronous, and DC assets. The default value is 60 seconds. To change the charge time,
click the down arrow and select from the list of between 15 and 600 seconds.
Test Button
Click Test to advance to the test window.
Save Button
Click Save when the test set-up selections are complete. This saves the settings as default
values for that asset for subsequent tests, but is not required. If you forget to save and click
Test, you will be asked if you want to save your changes.
Reset Button
Click Reset to set values back to the pre-changed value. Note: If you have clicked the
Save button they will not reset and it will be necessary to manually change them back.
Cancel Button
Click Cancel to close the Test Selection window without saving setup changes or
proceeding to the test window. You will be asked if you want to save test setup settings.

TEST WINDOW
Once the asset section and setup parameters are selected, you are ready to run the test.
This section explains each test by asset type and asset section. The test window is
discussed followed by step-by-step testing procedures. Test analysis information begins
on page 5-53.
AC Induction Assets
The MCE tests for an AC Induction asset are MCE Auto, AC Standard, Polarization
Index, RIC, and Step Voltage. They are discussed in detail in this section.
Note: To minimize the influence of stored energy on test results, perform the tests in the
following order. If a test is not to be performed, skip to the next test.
Standard Test
Polarization Index (PI)/Dielectric Absorption (DA) If a PI is performed, it is not
necessary to perform a separate DA.
Some circuits may have surge capacitors and power factor correction capacitors installed.
This is important since these components affect the values of the collected data and
increase the time and number of steps involved in troubleshooting. Testing can be
performed with the power factor capacitors installed. However, a test should be taken with
surge capacitors removed for future comparison. If an asset appears faulty with the power
factor capacitors installed, disconnect them and perform the testing again to isolate the
fault.
MCE Auto Test
MCE Auto test performs a standard test followed by a Polarization Index test, then saves
the data and produces a Fault Zone Report.
MCE Auto test can be started by clicking the MCE Auto icon on the toolbar or
selecting MCE Auto from the test list in the Test Selection Window. If you select the MCE
Auto icon, the MCE Auto test window opens bypassing the Test Selection window.
If you need to change the test setup settings, select the Test Selection icon . The Test
Selection window opens, make your changes, and then select MCE Auto from the test list
and click Test. The MCE Auto Test window, Figure 5-3, opens. The MCE Auto Test
window menu consist of three options: File, View, and Options.
Figure 5-3: MCE Auto Test Window
File Menu
Save. Save (Ctrl+S) is not active, it appears dimmed, until after testing is complete.
Exit. Exit (Ctrl+X) closes the MCE Auto Test and Test Selection windows and returns
you to the Home window.
View Menu
Create Message . Create Message
opens the Compose Asset Message
window (Figure 5-4). Messages created
here are viewed in the Message Center.
For more information on the Message
Center, see Chapter 3, page 3-41.
Figure 5-4: Compose Asset Message Window
Options Menu
Set Condition Code. Change the condition
code, by s el ect i ng t he opt i on but t on
corresponding to the condition (Figure 5-5). The
Asset Condition box on the MCE Auto Test
window changes and a note is automatically
generated by the software. The note is viewed in
the Message Center. For more information on
the Message Center, see Chapter 3, page 3-43.
Figure 5-5: Set Condition Code Window
Test Button
To begin testing click Test. During testing the menu items are dimmed (not available) and
the Test button changes to Stop. The test takes approximately 11 minutes.
The tester automatically proceeds from the Standard test to the Polarization Index (PI)
test. A status bar displays the testing progress. During the Standard test there is one Total
Test Progress bar. When the PI test is performed there is a PI progress bar, a Total Progress
bar, and a graph in the lower left displaying the test results. See Figure 5-6.
Figure 5-6: MCE Auto Test Window - PI Test
At the end of the PI test, the test results are automatically saved and the Fault Zone Report
is generated and displayed. See Figure 5-7.
Figure 5-7: MCE Auto Test Fault Zone Report
Fault Zone Report
File Menu
Print Preview. Print Preview, shown in Figure 5-8, displays the Fault Zone Report as it
will be printed. Using the File menu on the Print Preview window, you can export the
report to PDF or HTML or add comments before printing.
To create a PDF file, select File, Export to PDF, select the location you wish to save
the file in, enter a file name, and click Save.
To create a HTML file, select File, Export to HTML, select the location you wish to
save the file in, enter a file name and click Save.
To add comments, select File, Add Comments. In the Add Remarks window type your
comments and click Add. The comments appear in the Comments section at the
bottom of the report. They will appear on the printed report, but are not saved for the
future. Permanent comments should be entered in the Message Center using Edit,
Create Message, which is discussed on page 5-11.
To print the report click the Print icon on the Print Preview toolbar.
Figure 5-8: Print Preview
Print. Print prints the report to your default printer.
Exit (Ctrl+Q). Exit the report by using File, Exit (Ctrl+Q) or clicking the Close button
(red X in the upper right corner).
Edit Menu
Create Message (Ctrl+M). You may enter permanent notes by selecting Create
Message (Ctrl+M). This opens the Compose Asset Message window shown in Figure 5-4
on page 5-8. The note is viewed from the Message Center. See the section on Message
Center in Chapter 3, page 3-41.
Options Menu
Refresh (Ctrl+R). The Refresh function is used to update the Fault Zone Report when
changes have been made to the warning settings.
Set Condition Code. Change the condition code, by selecting an option button, the
Condition Code box changes, and a note is automatically generated by the software. The
note is viewed from the Message Center. See the section on Message Center, in Chapter 3,
page 3-43.
Description/Recommendation
The blank area at the bottom of the report is designed to provide additional information,
such as descriptions of the Fault Zones and Test Types or recommended actions for the
Condition Code. It is for on screen viewing only and does not appear on the printed report.
To view a description of the Fault Zone or Test Type, click on the name in the Fault Zone
report. The description will appear in the text box at the bottom of the window.
To view the recommended course of action for a condition code, click the condition
code name. The recommended course of action will appear in the text box at the bottom of
the window. Figure 5-7 shows how the window would appear if severe condition code of
the power circuit was selected.
To View Test History
To open the Test History click on the test type result value or the date. The Test History
window opens.
AC Standard Test
The AC Standard test is reach by selecting AC Standard from the test list on the Test
Selection window. See page 5-3, Test Selection Window for more information. Verify that
the test set-up settings are correct and click Test. The AC Standard Test Window (Figure
5-9) opens.
Figure 5-9: AC Standard Test Window
The AC Standard Test window menu consist of three options: File, View, and Options.
File Menu
Exit. Exit (Ctrl+X) closes the AC Standard test window and returns you to the MCEGold
Home window.
View Menu
Create Message. Creat e Message
wi ndow (Fi gure 5-10). Messages
created here are viewed in the Message
Center. For more information on the
Message Center, see Chapter 3, page 3-
41.
Options Menu
code, by selecting an option button (Figure 5-
11). The Asset Condi t i on box on t he AC
Standard Test window changes and a note is
automatically generated by the software. The
note is viewed in the Message Center. For more
information on the Message Center, see Chapter
3, page 3-43
Figure 5-11: Options, Set Condition Code Menu
Step-by-Step AC Standard Testing
1. Deenergize and lock out the starter and the asset.
2. Check for low level induced voltages using a Fluke multimeter or equivalent.
Verify that the values do not exceed 0.5 VAC phase-to-phase and 15 VAC phase-to-
ground. Check for low level stored voltage by verifying less than 15 VDC phase-to-
ground.
3. Connect the MCE to the circuit, in the same manner each time, as referenced in Table
5-1. This ensures that the test data is trendable/repeatable.
Table 5-1: Test Lead Connections
4. Highlight the asset to be tested on the Site Navigator.
MCE t es t
leads
Black White Red Green
motor phase A B C gnd
T lead T1 T2 T3 gnd
vertical top mid bot gnd
horizontal left mid right gnd
5. Select the Test Selection icon on the toolbar. The Test Selection window opens,
Figure 5-12.
6. Verify that the MCE (Test Type) and Stator (Asset Section) tabs are selected. The type
of asset determines which asset sections are available.
7. Click AC Standard from the Test List.
If all of the settings in the MCE Test Setup are correct, click Test to go directly to the
test. Go to step 16.
8. Verify the Test Location in the Test Setup section.
To insure consistent trending and assist in trouble shooting, the actual test location
should be stored for each test.
The Test Location default is Not Assigned. To assign a test location, click the down
arrow and select from the list. If the location is not known, click the browse
button . The Test Location Selection window opens displaying a test location
graph for the type of asset selected. Use the graph to determine the location, then click
the down arrow, select from the list, and click OK. See Figure 5-13.
Figure 5-13: Asset Test Location
9. Verify the Test Frequency.
Click the down arrow and select the frequency from the drop-down list. The values
are 300 or 1200.
10. Verify the Low Limit Shut Off condition.
Check the box to activate the low limit shut off and enter the desired Mohms.
11. Verify the Voltage.
Click the down arrow and select the voltage from the drop-down list. Select test
voltage based on asset nameplate voltage.
12. Enter the temperature.
Adjust the Temperature C to stator core temperature at the time of testing.
13. Select the Charge Time Seconds.
Click the down arrow and select the seconds from the drop-down list. The choices are
from 30 to 180 seconds at 15 second increments.
14. Click Save to save the settings for this asset for future testing. Or click Reset to return
the original settings. This can only be done if the new settings have not been saved.
15. Click Test to go to the testing window.

16. Click Test in the AC Standard Test Window.
17. Verify that you are about to apply X volts to the circuit by clicking Yes.
18. Testing begins, progress bars are displayed for Total Test Progress and Discharge
Progress at various times. The test values are filled in as testing proceeds. At the end
of testing Test Completed appears above the Nameplate Information area. See Figure
5-14.
To stop the test at any time, click Stop. Click Exit to close the AC Standard test
window and return to the Home window.
19. Click OK when the test is complete.
20. Re-test any individual point, if needed. If not go to step 21.
If any portion of the test needs to be re-tested, double click the tab which appears to
the right of the individual test point. This rechecks only that test point in manual
mode. See Figure 5-14.
Figure 5-14: AC Standard Test Window
21. When retesting is complete or if no re-testing is needed, click Save or select File,
Exit, or Ctrl+X, or use the close button (X in the upper right corner).
22. Click OK in the Save Complete window.
23. Click Exit in the AC Standard Test Window.
Polarization Index
The Polarization Index (PI) test is reached by selecting Polarization Index from the test list
on the Test Selection window. See page 5-3, Test Selection Window for more information.
Verify that the test set-up settings are correct and click Test. The PI test window opens.
See Figure 5-15.
Figure 5-15: PI Test Window
File Menu
Exit. Exit (Ctrl+X) closes the PI Test window and returns you to the Home window.
Options Menu
corresponding to the condition (Figure 5-16).
The Asset Condition box on the PI Test window
changes and a note is automatically generated by
the software. The note is viewed in the Message
Center. For more information on the Message
Step-by-Step Polarization Index Testing
The PI test takes ten minutes. During the test the menu items are dimmed (not available)
and the Test button changes to Stop.
ground.
3. Connect the MCE to the circuit, in the same manner each time, as referenced in Table
5-2. This ensures that the test data is trendable/repeatable.
Table 5-2: : Test Lead Connections
4. Highlight the asset to be tested in the Site Navigator.
Figure 5-17.
MCE t es t
leads
T lead T1 T2 T3 gnd
Figure 5-18: Asset Test Location
Click the down arrow and select the voltage from the drop-down list. Select the test
11. Click Test to go to the testing window.
12. Click Test in the PI Test window.
14. As the test proceeds, the test result values are displayed in the table and plotted on the
graph. At the end of one minute the D/A ratio is computed and displayed in the D/A
Ratio text box. The progress bar displays the progress of the testing.
Note: To stop the test, click Stop.
15. Click OK in the Test Completed window. The menu item become active and the Stop
button is inactive.
16. Exit the PI Test window by selecting File, Exit, or Ctrl+X, or the close button (Red X
in the upper right corner).
17. You will be asked if you want to save test data. Click Yes or No.
If you select Yes, click OK in the Save Completed widow. The PI Test window closes
If you select No, the PI Test window closes. No test data is saved.
RIC
The RIC test is reached by selecting RIC from the test list on the Test Selection window.
See page 5-3, Test Selection Window for more information. Verify that the test set-up
settings are correct and click Test. The RIC test window opens. See Figure 5-19.
Figure 5-19: RIC Test Window
File Menu
Exit. Exit (Ctrl+X) closes the RIC Test window and returns you to the Home window.
View Menu
Create Message . Cr eat e Mes s age
window (Figure 5-20). Messages created
here are viewed in the Message Center.
Options Menu
corresponding to the condition (Figure 5-21).
The Asset Condition box on the RIC Test
window changes and a note is automatically
the Message Center, see Chapter 3, page 3-41.
Step-by-Step RIC Testing
During the test the menu items are dimmed (not available). To stop testing, use File, Exit
which becomes active after each test point.
1. Deenergize and lock out the starter, disconnect, and the asset. Follow your companys
electrical safety procedures for tagouts.
Verify that the voltage does not exceed 0.5 VAC phase-to-phase and 15 VAC phase-
to-ground. Check for low level stored voltage by verifying less than 15 VDC phase-
to-ground.
3. Place the shaft key way in the up position. This ensures a common starting point for
all subsequent tests.
4. Ensure that the field is disconnected from the control circuit.
This is accomplished by isolating/removing the brushes from the slip rings or by
disconnecting the field leads from the diode pack in a self-exited asset. This allows
the natural magnetic field on the rotor to expand, enhancing the detection of rotor
problems.
5. Connect the MCE test leads to the circuit/asset, in the same manner each time, as
referenced in Table 5-3. This ensures that the test data is trendable/repeatable.
MCE t es t
leads
T lead T1 T2 T3 gnd
Figure 5-22.
of asset determines which asset section is available.
9. Select RIC from the Test List box.
Figure 5-23: Test Locations
12. Click Test to go to the test. The RIC test window, Figure 5-24, opens.
Figure 5-24: RIC Test Window
13. Verify that increments to be used during testing are correct. This information is
located at the top of the RIC Test window.
To change the Increments, which automatically computes the appropriate Degrees,
click the down arrow and select the increment from the drop-down list.
The new increments are displayed and the degrees on the test data table is updated.
14. Position the rotor to the first position and click Test to begin testing.
15. At the end of each test point, you will be reminded
to position the rotor for the next test point. Move the
rotor and click Test. Repeat until the end of the
recommended test.
As the test progresses, the values will be inserted into the table and displayed in the
graph areas. The magnification of the graphs can be changed by using the down
arrows below each graph area and selecting a new value from the drop down list. The
default is Full.
16. At the end of the recommended test you will be asked if you
want to continue. Select Yes to continue testing or No to end
testing.
17. Exit the RIC Test window by selecting File, Exit, or Ctrl+X, or
the close button (X in the upper right corner).
If you select Yes, click OK in the Save Completed widow. The
RIC Test window closes.
If you select No, the RIC Test window closes. No test data is
saved.
Step Voltage
The Step Voltage test is reached by selecting Step Voltage from the test list on the Test
the test set-up settings are correct and click Test. The Step Voltage Test window opens.
Figure 5-25.
Figure 5-25: Step Voltage Test
File Menu
Save. Save Data is not active, it appears dimmed, until after testing is complete.
Exit. Exit (Ctrl+X) closes the Step Voltage window and returns you to the Home window.
View Menu
Create Message. Cr eat e Mes s age
(Ct rl +S) opens t he Compose Asset
Mes s age wi ndow ( Fi gur e 5- 26) .
Messages created here are viewed in the
Message Center. For more information
on the Message Center, see Chapter 3,
page 3-41.
Figure 5-26: Compose Asset Message
Graph Option Menu
Show Current/Voltage. Show Current/Voltage controls the graph display area. If just
Current/Voltage is selected one graph displays on the window. If Show Current/Voltage
and Show Current/Time are both selected then two graphs will display.
Show Current/Time. Show Current/Time controls the graph display area. If just
Current/Time is selected one graph displays on the window. If Show Current/Time and
Show Current/Voltage are both selected then two graphs will display.
Overlay Graphs. Overlay Graphs controls the graph display area. When Overlay
Graphs is selected test results are graphed on one graph.
Line Style. Line Style controls the appearance
of the line on the graph.
Show Patterns changes the graph line style from
a solid to a pattern. When a change is made to
the line style it is reflected in the Legend area of
the window, which is located just above the
Nameplate Information.
Show Markers inserts markers on the graph line. When a change is made to the line style it
is reflected in the Legend area of the window, which is located just above the Nameplate
Information.
Options Menu
code, by selecting an option button (Figure 5-
27). The Asset Condition box on the Step
Voltage Test window changes and a note is
automatically generated by the software. The
note is viewed in the Message Center. For more
information on the Message Center, see Chapter
3, page 3-41.
Step-by-Step Step Voltage Testing
During the test the menu items are dimmed (not available).
to-ground.
MCE t es t
leads
T lead T1 T2 T3 gnd
Figure 5-28.
7. Select Step Voltage from the Test List box.
11. Click Test to go to the Step Voltage test window. See Figure 5-30.
Figure 5-30: Step Voltage Test Window
12. To begin the test click Test.
14. Test values are entered in the table on the left and are displayed in graph format on the
right side of the window. The magnification of the graphs can be changed by using
the down arrows below each graph area and selecting a new value from the drop
down list. The default is Full. A progress bar at the bottom of the screen tracks the
testing progress.
Note: During the test the Test button changes to Stop, which allows you to interrupt
the testing.
15. At the end of testing click OK in the Test Completed window.
16. Exit the Step Voltage Window by selecting File, Exit, or Ctrl+X, or
the close button (X in the upper right corner).
If you select Yes, click OK in the Save Completed widow. The
Step Voltage Test window closes.
If you select No, the Step Voltage Test window closes. No test data
is saved.
AC Synchronous Assets
The MCE tests for an AC Synchronous asset are MCE Auto, AC Standard, Polarization
Index, RIC, and Step Voltage for the Stator section and MCE Auto, Synchronous,
Polarization Index, and Step Voltage for the Field section.
Standard Test
Polarization Index (PI)/ Dielectric Absorption (DA). If a PI is performed, it is not
Synchronous assets are divided into two separate sections (Stator and Field Circuit). The
asset Section of the Test Selection window defaults to Stator.
Some asset circuits may have surge capacitors and/or power factor correction capacitors
installed. This is important since these components affect the values of the collected data,
and increase the time and number of steps involved in troubleshooting. Testing can be
performed with the power factor or surge capacitors installed. However, a test should be
taken with the surge capacitors removed for future comparison. If a asset appears faulty
with the power factor capacitors installed, disconnect them and perform the testing again
to isolate the fault.
Stator Section Test
MCE Auto
MCE Auto is the same as for an AC Induction asset. See MCE Auto on page 5-7.
AC Standard
AC Standard is the same as for an AC Induction asset. See AC Standard on page 5-12.
Polarization Index
Polarization Index test is the same as for an AC Induction asset. See Polarization Index on
page 5-16.
RIC
RIC test is the same as for an AC Induction asset. See RIC on page 5-20.
Step Voltage
Step Voltage test is the same as for an AC Induction asset. See Step Voltage on page 5-24.
Field Section Tests
MCE Auto
Polarization Index
page 5-16.
Step Voltage
Synchronous
The Synchronous test is reached by selecting the Field Tab and Synchronous from the test
list on the Test Selection window. See page 5-3, Test Selection Window for more
information. Verify that the test set-up settings are correct and click Test. The
Synchronous Test window opens. Figure 5-31.
Figure 5-31: Synchronous Test Window
File Menu
Exit. Exit (Ctrl+X) closes the Synchronous Test window and returns you to the Home
window.
View Menu
(Ctrl+S) opens the Compose Asset
Message window (Figure 5-32). The
note is viewed in the Message Center.
Figure 5-32: Compose Asset Message
Options Menu
code, by selecting an option button, the Asset
Condition box on the Synchronous Test window
Step-by-Step Synchronous Testing
During the test the menu items are dimmed (not available).
to-ground.
Figure 5-34.
MCE t es t
leads
T lead T1 T2 T3 gnd
6. Verify that the MCE (Test Type) and Field (Asset Section) tabs are selected. The type
7. Select Synchronous from the Test List box.
9. Verify the Test Frequency.
are 300 or 1200.
13. Select the Charge Time Seconds.
Click the down arrow and select the seconds from the drop-down list. The choices are
from 30 to 180 seconds at 15 second increments.
15. Click Test to go to the Synchronous test window.
16. Verify that you are about to apply X volts to the circuit and click Yes.
Progress at various times. The test values are filled in as testing proceeds.

18. At the end of testing the Test button changes to Save, Test Completed appears above
the Nameplate Information section, and the progress bars disappear.
If any portion of the test needs to be re-tested, click the tab which appears to the right
of the individual test point. This retests only that test point in manual mode. (Figure
5-36)
Figure 5-36: Completed Synchronous Test Window
20. When retesting is complete or if no re-testing is needed, click Save or File, Exit, or
Ctrl+X, or use the close button (X in the upper right corner).
21. Click OK in the Save Completed window.
22. Click Exit to close the window.
AC Wound Rotor Assets
Wound rotor assets (WRMs) are divided into three separate sections (Stator, Rotor, and
Resistor Bank). The asset Section box of the Test Selection window defaults to Stator.
The MCE tests for an AC Wound Rotor asset are MCE Auto, AC Standard, Polarization
Index, RIC, and Step Voltage for the Stator section. MCE Auto, AC Standard, Polarization
Index, and Step Voltage for the Rotor section. MCE Auto, Resistor Bank, Polarization
Index, and Step Voltage for the Resistor Bank section.
Standard Test
Polarization Index (PI)/ Dielectric Absorption (DA). If a PI is performed, it is not
Some circuits may have surge capacitors and power factor correction capacitors installed.
This is important since these components affect the values of the collected data, and
increase the time and number of steps involved in troubleshooting. Testing can be
performed with the power factor capacitors installed. However, surge capacitors must be
removed to ensure valid test data. If a asset appears faulty with the power factor capacitors
installed, disconnect them and perform the testing again to isolate the fault.
Stator Section Tests
MCE Auto
AC Standard
Polarization Index
page 5-16.
RIC
RIC test is the same as for an AC Induction asset. See RIC on page 5-20.
Step Voltage
Step Voltage test is the same as for an AC Induction asset. See Step Voltage on page 5- 24.
Rotor Section Tests
MCE Auto
AC Standard
Polarization Index
page 5-16.
Step Voltage
Step Voltage test is the same as for an AC Induction asset. See Step Voltage on page 5- 24.
Resistor Bank Section Tests
MCE Auto
Polarization Index
page 5-16.
Step Voltage
Resistor Bank Test
The Resistor Bank test is reached by selecting the Resistor Bank tab and Resistor Bank
from the test list on the Test Selection window. See page 1-3, Test Selection Window for
more information. Verify that the test set-up settings are correct and click Test. The
Resistor Bank Test window opens. Figure 5-37.
Figure 5-37: Resistor Bank Test Window
File Menu
Exit. Exit (Ctrl+X) closes the Resistor Bank Test window and returns you to the Home
window.
View Menu
Options Menu
code by selecting an option button (Figure 5-39).
The Asset Condition box on the Resistor Bank
Test window changes and a note is automatically
generated by the software.
Step-by-Step Resistor Bank Testing
to-ground.
3. Lift the brushes to isolate the resistor bank from the rotor field.
MCE
t es t
leads
brushes br ushes
over slip
ring 1
br us hes
over slip
ring 2
br ushes
over slip
ring 3
gnd
Figure 5-40.
7. Verify that the MCE (Test Type) and Resistor Bank (Asset Section) tabs are selected.
The type of asset determines which asset sections are available.
8. Select Resistor Bank from the Test List box.
14. Click Test to go to the Resistor Bank Test window.
15. To begin the Resistor Bank Test, click Test.
16. Verify that you are about to apply X volts to the circuit and click Yes.
of testing Test Completed appears above the Nameplate Information area.

If any portion of the test needs to be re-tested, click the green arrow to the right of the
point. This rechecks only that test point in manual mode. See Figure 5-42.
Figure 5-42: Resistor Bank Test Window - Retest Points
19. When retesting is complete or if no re-testing is needed, click Save, or File, Exit, or
Ctrl+X, or the close button (X in the upper right corner).
20. Click OK in the Save Completed window and the Resistor Bank Test window closes.
DC Assets
The MCE tests for a DC asset are MCE Auto, DC Standard, Polarization Index, Bar-to-
Bar, and Step Voltage for the Armature section. MCE Auto, DC Standard, Polarization
Index, and Step Voltage for the Field section.
Standard Test
Polarization Index (PI). If a PI is performed, it is not necessary to perform a separate
DA.
DC assets are divided into two separate sections (Armature Circuit and Field Circuit). The
Asset Section of the Test Selection window defaults to Armature Circuit.
Armature Section Tests
MCE Auto
DC Standard Test
The DC Standard Test is reached by selecting DC Standard from the test list on the Test
the test set-up settings are correct and click Test. The DC Standard Test Window (Figure
5-43) opens.
Figure 5-43: DC Standard Test Window
The DC Standard Test window menu consist of three options: File, View, and Options.
File Menu
Exit. Exit (Ctrl+X) closes the AC Standard test window and returns you to the MCEGold
Home window.
View Menu
Create Message. Creat e Message
window (Figure 5-44). The note is
viewed in the Message Center. For
more information on the Message
Options Menu
code by selecting an option button (Figure 5-45).
The Asset Condition box on the AC Standard
Test window changes and a note is automatically
the Message Center, see Chapter 3, page 3-43
Figure 5-45: Options, Set Condition Code Menu
Step-by-Step DC Standard Testing
1. Deenergize and lock out the starter and asset.
2. Check for low level induced voltage using a Fluke multimeter or equivalent.
ground.
3. Connect the MCE test leads to the circuit, in the same manner each time, as
referenced in Table 5-7 and shown in Figure 5-46. This ensures that the test data is
trendable/repeatable.
Figure 5-46: DC Asset Circuit Connections
6. Verify that Armature Circuit is selected in the asset Section box.
7. Select DC Standard Test in the Test List box.
MCE t es t
leads
Black White Green
motor leads A1;
A1 or S1
A2;
S2 or A2
ground
Figure 5-47: DC Asset Test Location
9. Select Test frequency for the Armature Circuit from the drop-down box.
are 300 or 1200.
10. Check the Low Limit Shut Off box and enter Mohms.
11. Select the test voltage for the resistance to ground measurement (500 for < 2400 volts
or 1000 for >2400 volts) based on asset nameplate voltage.
Click the down arrow and select the voltage from the drop-down list.
12. Adjust the Temperature C to stator core temperature at the time of testing.
13. Select Charge Time seconds.
Click the down arrow and select the charge time from the drop-down list. The choices
are from 15 to 600 seconds.

14. Click Save, to save the settings for this asset for future testing. Or click Reset to
return the original settings. This can only be done if the new settings have not been
saved.
15. Click Test to go to the DC Standard Test Window.
16. Click Test to begin testing.
of testing Test Completed appears above the Nameplate Information area. See Figure
5-48.
To stop the test at any time, click Stop. Click Exit to close the DC Standard test
window and return to the Home window.
If any portion of the test needs to be re-tested, double click the tab which appears to
the right of the individual test point. This rechecks only that test point in manual
mode. See Figure 5-48.
Figure 5-48: DC Standard Test Window
20. When retesting is complete or if no re-testing is needed, click Save or select File,
Exit, or Ctrl+X, or use the close button (X in the upper right corner).
21. Click OK in the Save Complete window.
22. Click Exit in the DC Standard Test Window.
Step-by-Step Polarization Index Testing
1. Deenergize and lock out the starter asset.
2. Check for low level induced voltage using a Fluke multimeter or equivalent.
ground
3. Connect the MCE test leads to the circuit, in the same manner each time, as
referenced in Table 5-8 and shown in Figure 5-49. This ensures that the test data is
trendable/repeatable.
Figure 5-49: Asset Circuit Connections
6. Verify that Armature is selected.
7. Select Polarization Index in the Test List Box.
MCE t es t
leads
Black White Green
motor leads A1;
A1 or S1
A2;
S2 or A2
ground
9. Check the Low Limit Shut Off box and enter Mohms.
10. Enter the test voltage for the resistance to ground measurement (500 for < 2400 volts
or 1000 for >2400 volts) based on asset nameplate voltage.
Click the down arrow and select the voltage from the drop-down list.
11. Click Save, to save the settings for this asset for future testing. Or click Reset to
return the original settings. This can only be done if the new settings have not been
saved.
12. Click Test to go to the PI Test Window. See Figure 5-51.
Figure 5-51: PI Test Window
13. Select the test length in seconds from the drop down list.
14. Click Test to begin testing.
To stop the test at any time, click Stop. Click Exit to return to the Test Selection
window.
16. During the testing the D/A ratio and the Polarization Index will be computed and
entered in the appropriate text boxes on the window.
17. Click OK at the end of testing in the Test Complete window.
18. Close the PI Test window by selecting File, Exit, or Ctrl+X, or the close button (red X
in the upper right corner).
19. Click Yes to save test data, in the Save Test Data window. Or No to exit without
saving test data.
20. Click OK in the Save Completed window.
Step Voltage
Bar-to-Bar
The Bar-to-Bar test is reached by selecting the Armature tab and Bar-to-Bar from the test
list on the Test Selection window. See page 5-3, Test Selection Window for more
information. Verify that the test set-up settings are correct and click Test. The Bar-to-Bar
Test window opens. Figure 5-52.
Figure 5-52: Bar-to-Bar Test Window
File Menu
Exit. Exit (Ctrl+X) closes the Bar-To-Bar Test window and returns you to the Home
window.
View Menu
Options Menu
code by selecting the desired condition code
opt i on but t on ( Fi gur e 5- 54) . The Asset
Condition box on the Bar-To-Bar Test window
Raise Leads/Lower Leads Button
The Raise Leads/Lower Leads button toggles to signify the action to be taken with the test
leads during testing.
Exit Button
The Exit Button is inactive (dimmed) during testing, but is active between moving the
leads.
Pause Button
The Pause Button is inactive (dimmed) during testing, but is active between moving the
leads.
Test
The lower left area of the Bar-to-Bar test window, Figure 5-55, informs you what action is
required. The Test Dialog box displays the testing progress. The software checks for the
leads and if no leads are found displays, Waiting for Leads in the text box. When the
leads are in position, testing begins automatically. During testing the text box displays
Read Resistance, Checking Leads, Test Completed, Waiting for Leads.
Figure 5-55:
Step-by-Step Bar-to-Bar Testing
ground.
3. Connect the bar-to-bar test leads to the MCE and to the laptop parallel port.
4. Highlight the asset to be tested on the Site Navigator.
Figure 5-56.
6. Verify that the MCE (Test Type) and Armature (Asset Section) tabs are selected. The
type of asset determines which asset sections are available.
7. Click Bar-To-Bar from the Test List.
9. Verify the Span is correct.
11. Click Test to go to the testing window
12. To begin the Bar-to-Bar Test, click Test.
13. When Waiting for Leads appears in the Test Dialog Box, position the leads. Testing
will begin automatically. The dialog box will inform you of the testing progress
beginning with Read Resistance, Checking Leads, and finally Test Complete. See
Figure 5-58.
Figure 5-58: Test Dialog Box
14. During testing the test values are entered in the table on the left and are displayed in
graph format in the center of the window. The magnification of the graph can be
changed by using the down arrows below the graph area and selecting a new value
from the drop down list. The default is Full.
15. When Test Complete appears in the Test Dialog box, reposition the leads. Testing will
begin automatically.
16. Repeat Step 14 until all bars have been tested.
17. At the end of testing, you will be asked if you want to continue testing. Click Yes to
continue or No to end testing.
18. Click Exit. You will be asked if you want to save test data.
Click Yes to save the test data. Click OK in the Save Completed window. The Bar-to-
Bar test window closes.
Or click No to exit the window without saving.
Field Section Tests
MCE Auto
DC Standard
DC Standard test for the Field section is the same as for the Armature section. See DC
Standard on page 5-40.
Polarization Index
The Polarization Index test for the Field section is the same as for the Armature section.
See Polarization Index on page 5-45.
Step Voltage
TEST DATA ANALYSIS INFORMATION
Standard Test
The standard test is similar for both AC and DC assets. In an AC asset, the following are
either measured or calculated during a standard test:
Resistance-to-ground
Capacitance-to-ground
Resistance phase-to-phase
Inductance phase-to-phase
Resistive imbalance (calculated)
Inductive imbalance (calculated)
Power loss
In a DC asset, the following are either measured or calculated during the standard test:
Resistance-to-ground
Capacitance-to-ground
Armature and/or field resistance
Armature and/or field inductance
Resistance-to-Ground
What Does it Tell You?
The resistance-to-ground (RTG) measurement indicates the cleanliness and health of the
insulation system. As the insulation ages, cracks and small holes develop. It also becomes
brittle over time, as the wiring expands due to heating and contracts when it cools off.
Aging and temperature variations also break down the molecular structure of the
insulation.
These factors allow contaminants and moisture, which collect on the surface of the
insulation, to penetrate to the conductor. Since current follows the path of least resistance,
some of the total current is diverted from the circuit to these alternate paths, and ultimately
to ground. As the RTG value decreases over time, capacitance-to-ground often increases,
indicating the presence of many current leakage paths to ground and the accumulation of
contaminants.
Why is This Important?
A low RTG value indicates that the insulation needs to be cleaned. If the condition causing
the low RTG is not corrected and the RTG value continues to drop, the insulation could
completely fail and the asset windings could be damaged. This could require a complete
rewind of the stator. If the condition causing the low RTG is corrected, a less expensive
clean, dip, and bake may suffice.
Setting Warning Levels
Minimum Value. IEEE (the Institute of Electrical and Electronics Engineers, Inc.) has
established a standard for the minimum value of insulation resistance which can be
applied to most AC windings, DC armature windings, and AC and DC field windings. The
standard is IEEE Std 43-2001. The equation for most windings made circa 1970 or before,
all field windings, and others not noted in the exceptions listed below is IR
1min
=kV+1.
In the formula:
IR
1min
is the recommended minimum insulation resistance-to-ground, in megohms, at
40C (104 F) at the asset windings
kV is the rated terminal-to-terminal potential, in RMS kilovolts
Examples
A 480 volt asset has a minimum RTG value of 1.48 megohms (480 volts = .480
kilovolts; .48 + 1 = 1.48 megohms)
A 4160 volt asset has a minimum RTG value of 5.160 megohms (4160 volts = 4.160
kilovolts; 4.160 + 1 = 5.160 megohms)
MCEGold computes the minimum acceptable RTG value using this equation. This value
is corrected to 40 C. MCEGold provides both the temperature corrected RTG reading
along with the actual measured RTG value. To make comparisons and trending valid,
always enter actual asset winding temperature and trend the corrected measurement.
Exceptions to the equation are:
Most DC armature and AC windings built circa or after 1970 (form wound coils).
That standard is IR
1 min
= 100.
Most machines with random-wound stator coils and form-wound coils rated
below 1 kV. That standard is IR
1min
= 5.
Stator of AC Induction, Synchronous, and Wound Rotor Assets;
Field and Armature of DC Assets
If the corrected RTG is between R
m
and 2 times R
m
, then the value is set at caution. The
reading appears in yellow on the tester display or underlined on a printed copy of the Test
History. If the reading is less than R
m
, the value is set at alarm. The reading appears in red
on the tester display or bolded on a printed copy.
Wound Rotors, Resistor Banks
Voltages in wound rotors and their three-phase resistor banks are typically too low to use
the minimum resistance equation to figure minimum values. The warning levels should be
set based on your experience. Establish a baseline test for new assets and assets tested for
the first time, and watch the trends. Compare values on similar assets operating under
similar conditions.
Exceptions
Some assets may show insulation resistance readings which are lower than the IEEE
recommended minimum value and still have good insulation. These include:
Windings with an extremely large surface area
Large or slow-speed assets
Assets with commutators
A DC armature with a low RTG value typically has multiple paths for leakage current, not
just one. Because of this, finding the exact location of ground faults is almost impossible
and repair is very difficult. This problem is much more complex than in AC assets.
Therefore, lower minimum acceptable RTG values are generally tolerated. In these cases,
the IEEE standard of IR
1min
= kV + 1 is typically relaxed to IR
1min
= kV.
Out-of-service assets, without installed heaters operating, may absorb enough moisture to
lower insulation resistance to less than the recommended limits.
Interpreting Readings
There are two factors, which require user input, which affect the value of RTG
measurements. They are temperature and charge time. In order to compare temperature-
corrected RTG readings for similar assets operating under similar conditions, these factors
MUST be taken into account.
Temperature
The Test Selection window uses the IEEE standard reference value of 40C as the default
value for the winding temperature. This can be changed. The corrected RTG reading
shown at the end of the test and in the Test History is the value that would be expected at
40C regardless of the actual temperature of the asset winding insulation when the test
was performed. In other words, if the reading is always corrected to the same temperature,
then temperature is removed as an influencing factor. This allows you to use the corrected
RTG value from test to test as a valuable trending tool.
Temperature correction is necessary since the resistance of an insulation material
decreases significantly as its temperature increases. The materials which make up
insulation have a negative temperature coefficient (inversely proportional). In other
words, as the temperature increases their ability to stop current flow decreases. This
means it is necessary to know the temperature of the asset when determining the condition
of the insulation system.
Therefore, as the temperature of the asset increases, the measured insulation resistance
decreases. To compare the reading you got today with a reading you got last month, it is
important that you compare like results. The way to do this is to calculate the corrected
resistance to a given temperature. MCE resistance values are corrected to a standard
temperature of 40C. This temperature is selected because the normal operating
temperature for an asset is typically approximately 40C (104F). When comparing the
results of different tests note the temperature input for possible variations.
Table 5-9 shows the report results for the same insulation with resistance to ground
measurements taken at a variety of temperatures and compensated to different
temperatures.
Table 5-9: Temperature Compensation
It can be seen from the chart that if temperature compensation is not performed, the
reported (actual) resistance to ground changes with temperature. When temperature
compensation is performed, the reported resistance does not change when the test
temperature changes. In order to compare results, all measurements MUST be
compensated to the same temperature.
Test Voltage and Charge Time
The ground wall insulation in a asset has a conductor on either side. On one side of the
insulation is the stator windings, the conductors that make up the individual coils in each
pole group for each phase. On the other side is the stator core, formed by the stator
laminations connected to the frame/casing of the asset. This design has the fundamental
components which make up a capacitor. When a DC potential is applied, the insulation
charges the way a capacitor does. This is important because if the resistance to ground
reading is recorded as soon as the test potential is applied, it is lower than if it is recorded
after the insulation is charged.
A rule of thumb for performing RTG measurements is to apply the test potential for 1
minute or until the reading has stabilized. This allows for different technicians to obtain
values from test to test which can be compared. However, this is not very accurate. On the
MCE, the duration of time the voltage is applied to the insulation system is selectable.
Test voltage potential can be from 250 to 5000 volts, based on asset nameplate voltage.
Charge time can be set between 15 and 600 seconds, at 15 second intervals. Defaults are
set at 500 volts and 60 seconds. Again, using the same values every time makes
comparison and trending a valuable tool.
Data Interpretation
If the RTG value is low, isolate the problem to either the power circuit or the asset.
Assuming the first test was made at the MCC, perform another test at the asset connection
box. Disconnect the asset leads and test the asset. If the RTG value is higher testing the
asset, the fault is in the cables between the MCC and the asset. Check the connections in
the asset connection box, look for moisture in the conduit, and examine the cables. The
cables may require cleaning, drying, or replacement.
If the RTG value at the asset connection box is still low, the fault is in the asset. If the
value is in caution, the asset may need to be dried, cleaned in place, or removed for a
clean, dip, and bake. If the value is in alarm, the asset may need to be rewound. If the RTG
value is less than the IEEE minimum, look for a ground fault and clear this condition
before starting the asset.
Temperature Actual Resistance 25 C Compensated 40 C Compensated
20 C 20 Megaohm 14 Megaohm 5 Megaohm
45 C 3.5 Megaohm 14 Megaohm 5 Megaohm
50 C 2.5 Megaohm 14 Megaohm 5 Megaohm
Examples
A conveyor asset was tested and had <.1 Megohm RTG. When the technician removed the
terminal box cover, he found that one of the taped connections had arced to ground. The
leads were repaired and the asset was retested. RTG increased to 263 Megohms.
A compressor asset was tested and had <.1 Megohm RTG. When the technician removed
the terminal box cover, he saw that the box was half full of water. The leads were dried
and the asset was retested. RTG increased to 21.5 Megohms
Capacitance-to-Ground
The capacitance-to-ground (CTG) measurement is indicative of the cleanliness of the
windings and cables. As dirt and contaminants build up on windings and cables, CTG
values increase. An increasing trend showing rising CTG values indicates that the asset
needs to be cleaned.
A capacitor is formed by any two conducting materials, called plates, separated from each
other by a dielectric material. Dielectric material is anything that is unable to conduct
direct electric current. A cable or winding surrounded by insulation provides one
conductor and the dielectric material. The second plate is formed by the stator core and
casing iron.
Normally, when the outside of the insulation is clean and dry, it is not a good conductor.
When dirt, moisture, and other contaminates begin to cover the stator windings inside the
asset, they cause the outer insulation surface areas to become conductive. Since this
surface is in contact with the ground, it allows an AC current path to ground. Cables in the
power circuit are also subjected to the same affect, when moisture penetrates the outer
casing. The cleanliness of the windings and cables can be determined by looking at the
CTG value.
With a buildup of material on them, dirty windings and cables produce higher capacitance
values than clean ones do. Over time, CTG values steadily increasing indicate an
accumulation of dirt and that cleaning is necessary. This can be correlated with decreasing
RTG values.
Dirt and contamination also reduce a assets ability to dissipate the heat generated by its
operation, resulting in premature aging. A general rule of thumb is that insulation life
decreases by 50% for every 10 C (50 F) increase in operating temperature above the
design temperature of the insulation system. This holds true with the asset operating at or
above a 75% load. Heat raises the resistance of conductor materials and breaks down the
insulation. These factors accelerate the development of cracks in the insulation, providing
paths for unwanted current to flow to ground. If capacitance is higher than normal, a low
RTG reading is an indication that such a path already exists.
Preset warning levels for CTG values in MCEGold are based on a percent change from the
baseline measurement. This is merely a comparison warning. A 100% increase from
baseline produces a caution (yellow on the computer display or underlined on the printed
copy). A 200% increase from baseline produces an alarm (red on the computer display or
bold on the printed copy). These values are guidelines. As you gather data on a single
asset or on similar assets operating in the same environment, reset the warning levels to
reflect your specific conditions.
Data Interpretation
Capacitance-to-ground is a function of many factors. Therefore, comparison of CTG
values is more revealing of a assets condition than is the analysis of a single snapshot
CTG value. For example, capacitance to ground is influenced by the design of each
individual asset, the length of the cable between the MCE and asset, the type of insulation
on the cables and asset windings, and the number and type of connectors in the circuit.
A new or recently refurbished asset may have a very low CTG reading. A normal
capacitance value can vary from asset to asset and is NOT an absolute value. CTG must be
analyzed by trending readings on the same asset or by comparing values taken on similar
assets, with similar histories, operating under the same conditions. If CTG increases over
time, dirt, moisture, and/or contaminants are building up on the windings, cables, or both.
Surge capacitors are used in some circuits and will affect CTG readings. Whenever
possible, CTG tests should be performed with the capacitors in the circuit as well as
disconnected, to indicate the health of the capacitors. This allows for trending the
condition of the capacitors as well as the CTG of the asset.
Examples
Capacitors and surge caps were left in the circuit for tests of two chillers used to cool vital
computers. Table 5-10 shows how several values were affected. Notice the difference in
the readings when the power factor capacitors were removed.
Table 5-10: Effects of Power Correction Capacitors
A conveyor asset was tested and had <.1 Megohm RTG and 999,999 pF CTG. When the
technician removed the terminal box cover, he found that one of the taped connections had
arced to ground. The leads were repaired and the asset was retested. RTG increased to 263
Megohms and CTG decreased to 67,750 pF.
A compressor asset was tested and had <.1 Megohm RTG and 83,000 pF. When the
technician removed the terminal box cover, he saw that the box was half full of water. The
leads were dried and the asset was retested. RTG increased to 21.5 Megohms and CTG
decreased to 8,000 pF.
With Power Factor
Capacitors Installed
With Power Factor
Capacitors Removed
Chiller #1 Chiller #2 Chiller #1 Chiller #2
Balance of
Resistance
1.74% 2.164% 0.050% 2.000%
Balance of
Inductance
16.0% 0.520% 2.560% 0.500%
CTG 999,999 pF 999,999 pF 38,750 pF 37,250 pF
RTG 0 Megohms 0 Megohms >2,000 Megohms > 2,000 Megohms
Phase-To-Phase Resistance
Phase-to-phase resistance is the measured DC resistance between phases of the stator in an
AC asset and between polarities of the armature and field coils in a DC asset.
In AC induction assets, use the phase-to-phase resistance values and resistive imbalances
for trending, troubleshooting, and quality control. In DC assets, use trending and relative
comparison to determine the condition of the phases in the asset and power circuits. This
includes comparing readings taken from identical assets operating in similar conditions
and comparing current readings against past readings for the same asset.
An increasing resistive imbalance or a changing resistance over time can indicate one or
more of the following:
High resistance connections
Coil-to-coil, phase-to-phase, or turn-to-turn current leakage paths
Corroded terminals or connections
Loose cable terminals or bus bar connections
Open windings
Poor crimps or bad solder joints
Loose, dirty, or corroded fuse clips or manual disconnect switches
Loose, pitted, worn, or poorly adjusted contacts in asset controllers or circuit
breakers
Mismatched components (incompatible materials, wrong sizes, etc.)
Undersized conductors (misassembled or improperly engineered)
Circuit resistance is determined by the length, size, width, composition, condition, type
and temperature of the conductors and connectors. When two different conductors are
connected, dirt, corrosion, or an improper connection increases the circuit resistance.
Also, inadequate connections cause heating of the conductor, which increases resistance
even more. This could be caused if only a few strands of a conductor or portions of a
soldered joint are improperly connected to a terminal or if undersized connectors are used.
In a three-phase asset circuit, the resistance in the conductor paths should be balanced. A
resistive imbalance occurs when the phases have unequal resistances. The formula
below shows that a very small resistive imbalance results in a high voltage imbalance.
This produces uneven current flow and excessive heat.
In the formula:
Vimb = voltage imbalance
Rmax = maximum winding resistance value
Rmin = minimum winding resistance value
Vimb
2
3
--- Rmax Rmin ( ) FLA
Vl
2
3
---

Rmax Rmin ( ) FLA

-----------------------------------------------------------------------------------------x100 =
FLA = full load amp rating of asset
Vl = line voltage
100 = converts number to percentage
When voltage applied across three-phase asset leads is unbalanced, circulating currents,
called negative sequence currents, are induced. When these negative sequence currents
are present, they cause heating in the windings. EPRIs (the Electric Power Research
Institute) Handbook to Assess the Insulation Condition of Large Rotating Machines states
a 3.5% voltage imbalance can raise winding temperature 25% in the winding(s) affected
by such currents. EASA (the Electrical Apparatus Service Association) says a 1%
voltage imbalance results in a 6-7% current imbalance.
The most extreme case of resistive imbalance occurs when a asset single phases. This
single phasing quickly causes the asset to fail because the remaining two phases
compensate by increasing current by 200% to 300% of normal. Rapid heating of the
windings which are still connected destroys the insulation surrounding them.
Resistance to the flow of current in a circuit is of concern from the standpoints of safety,
energy conservation, and insulation life. High resistance points in conductors generate
heat both at the point where the resistance is located and in the three-phase assets being
supplied.
Regardless of the source, some of the effects of increased heat production in the asset
include:
Higher resistance due to heat in conductor materials adjacent to the fault
Deterioration (accelerated aging) of the surrounding and supporting insulating
materials
Imbalance in multi-phase circuits, which adversely affects equipment
performance and life
Increased power consumption in all cases
Fire or failure in extreme situations
The preset warning levels in MCEGold are based on both actual values and on a % change
from the baseline value.
Data Interpretation
Resistive imbalance above the setpoint indicates that a problem exists in either the power
circuit or in the stator windings. First, isolate the problem to the asset or the circuit.
Looking at individual resistance readings can help isolate the problem to a phase. Also,
look for the following characteristics which indicate faulty connections.
Aluminum cables connected to lugs marked for copper wire only
Discoloration of insulation or contacts
Damaged insulation having small cracks, bare conductors, or metal components
Mismatched cables in common circuits
Poor lug crimps on T-Leads
Oxidation of conductor metals
Presence of contaminants such as dirt
Example
The following information is from a 7,000 HP vertical reactor coolant pump asset at a
nuclear power plant. A high resistance solder joint between phases 1 and 3 produced a
resistive imbalance of 37.15%. The cost associated with the power loss was calculated to
be $58,517.84 per year. Multiple tests, shown in Table 5-11, were performed to verify the
problem.
Table 5-11: MCE Tests Used in Troubleshooting Efforts
Phase-to-Phase Inductance
In AC assets, phase-to-phase inductance readings can:
Indicate the condition of the stator windings
Detect phase-to-phase and coil-to-coil current leakage paths
Reveal poor or incorrect rework
These readings can also be used to detect faults in power cables. A Rotor Influence Check
(RIC) can be performed to further troubleshoot the asset to reveal faults such as:
Broken/cracked rotor bars or end rings
Porosity and lamination damage
Eccentricity problems
In DC assets, inductance changes within the field or armature can indicate current leakage
paths in the windings.
Test Date 5/31/96 5/31/96 5/31/96
Test ID: 331 332 333
Frequency 1200 1200 1200
BASELINE
Mohm Ph 1 to Gnd
Charge Time 30 30 30
Voltage 1000 1000 1000
Motor Temp 40 40 40
Measured Mohm >2000 >2000 >2000
Corrected Mohm OVR OVR OVR
pF Ph 1 to Gnd 116250 116250 116250
ohm Ph 1 to 2 0.27450 0.26800 0.27400
ohm Ph 1 to 3 0.43750 0.43700 0.44100
ohm Ph 2 to 3 0.24500 0.24300 0.24200
mH Ph 1 to 2 6.750 6.750 6.750
mH Ph 1 to 3 6.755 6.750 6.750
mH Ph 2 to 3 6.745 6.745 6.745
% Res. Imbalance 37.15 38.29 38.24
% Ind. Imbalance 0.07 0.05 0.05
$ Power Loss 58517.84 58973.83 60493.78
Inductance changes when leakage paths develop. These paths can be either within the
winding coils, or directly to ground. Leakage paths result from mechanical, thermal,
environmental, or electrical damage to the insulation system of the windings. Additionally
phase-to-phase and turn-to-turn shorts can occur. In either case, current flow bypasses
some coils, thereby reducing inductive reactance and increasing current in other phases of
the stator. Temperature rises in the remaining conductors and in the surrounding
insulation. This accelerates the deterioration, which can cause an avalanche effect, as heat
produces more insulation failures, resulting in more leakage paths and more coils removed
from the circuit, further increasing temperature.
As there are fewer winding turns in a given phase actively creating the magnetic field
upon which the asset is functioning, the windings in the other phases compensate to meet
the requirements of the load on the asset. These windings in turn draw more current than is
normally supplied by a balanced asset.
A large inductive imbalance causes torque-induced vibration at two-times line frequency
(2F
L
). This vibration can be linked to mechanical degradation. Also, inductive imbalance
can contribute to other problems, among which are:
Bearing damage
Coupling damage
Loosened rotor bars
Insulation failure at winding end turns or at exit of stator slots
The preset warning levels in MCEGold are based on both actual values and on a change
from the baseline value.
Data Interpretation
Many factors affect inductance readings, including asset winding coils, the stator iron, the
rotor, and the number of rotor bars. The power circuit has little or no effect on the
inductance readings unless there are power factor or surge capacitors in the circuit.
Power correction and surge capacitors are used in some circuits and will affect phase-to-
phase inductance readings. Whenever possible, phase-to-phase inductance tests should be
performed with the capacitors in the circuit as well as disconnected, to indicate the health
of the capacitors. This allows for trending the condition of the capacitors as well as the
phase-to-phase inductance of the asset.
If both inductive and resistive imbalance are high, look for a leakage path in a coil or an
open coil. If resistive imbalance is low, the fault may be in the rotor.
A rotor bar/cage anomaly may not produce a large inductive imbalance on one single test.
If inductive imbalance has increased or is high, perform a RIC to further define the
problem. Excessive vibration can also be an indicator of inductive imbalance. If you
notice high vibration readings, perform a RIC to collaborate the data.
Example
A new asset with a cast aluminum rotor was load-tested prior to installation. The asset
failed to reach rated HP. A RIC was conducted and indicated the presence of broken rotor
bars.
When the rotor bars were cast, high resistance connections were formed. Operating the
asset during the load-test produced excessive heat at those points. The melted paint on the
rotor identified the high resistance connections beneath them.
Test Lead Check
The MCE verifies the resistance of the test leads before and after each test. This ensures
test lead continuity and proper connection prior to running the test. If any test lead
resistance exceeds a predetermined value, the MCE stops the test. That lead must then be
reconnected and retested successfully to continue. This ensures maximum accuracy and
repeatability of the collected data.
Resistive Imbalance
Resistive imbalance is calculated from the three individual phase-to-phase resistance
readings taken during the standard test. It is displayed as a percentage and will be put into
a caution or alarm state if it exceeds a specific limit. This limit can be changed in the
MCEGold software. Because this value is calculated from three phase-to-phase readings,
there is no resistive imbalance value for DC assets.
In AC assets, resistive imbalance is an indication of one or more high-resistance
connections in the circuit or shorted turns. Assuming the original test was performed at the
MCC, isolate the problem to the asset or to the power circuit by retesting the asset at the
connection box. If the resistive imbalance remains, the problem is in the asset. If the
resistive imbalance goes away, the problem is in the cables or power circuit. Look at the
individual resistance readings to determine the faulty phase.
Inductive Imbalance
Inductive imbalance is calculated from the three individual phase-to-phase inductance
readings taken during the standard test. It is displayed as a percentage and will be put into
a caution or alarm state if it exceeds a specific limit. This limit can be changed in the
MCEGold software. Due to the fact that this value is calculated from three phase-to-phase
readings, there is no inductive imbalance value for DC assets.
In AC assets, this calculated value can indicate the condition of the stator and rotor/stator
relationship. Turn-to-turn or phase-to-phase shorts in the stator causes a high inductive
imbalance. Rotor/stator eccentricity causes a varying value of inductive imbalance, as
seen on subsequent standard tests. To isolate a problem to the rotor or the stator, perform a
Rotor Influence Check.
Power factor capacitors, line reactors, and other power correction devices can impact
inductance values. Separation of these devices from the circuit may be required when
troubleshooting the asset.
Average Inductance
Average inductance is calculated from the three individual phase-to-phase inductance
readings taken during the standard test. Due to the fact that this value is calculated from
three phase-to-phase readings, there is no inductance imbalance value for DC assets. In
AC assets, this calculated value can indicate the condition of the rotor and rotor/stator
relationship. Rotor defects will cause an increase in the average inductance. To isolate a
problem to the rotor or the stator, perform a Rotor Influence Check.
Polarization Index Test
The Polarization Index (PI) and Dielectric Absorption (DA) ratios indicate the condition
of the insulation system of the asset and power circuit. Both of these tests use ratios of
measurements of insulation resistance taken at two different times. The PI is the ratio of
the reading taken at 10 minutes and divided by the reading taken at 1 minute. The DA is
the ratio of the reading taken at 60 seconds divided by the reading taken at 30 seconds.
There are three different currents that flow through an insulator when a voltage potential is
applied. Since the RTG test measures the voltage and current to calculate insulation
resistance, all of these currents must be taken into account.
First, the capacitive current starts out high and drops to nearly zero after the
insulation has been charged to full test voltage. This is normally negligible after
the first few seconds of the test.
Second, the absorption current also starts out high and drops off. The majority
of this current dissipates after one minute, but continues to decay for up to 5 to 10
minutes.
Finally, the conduction or leakage current is a small, mostly steady current
which becomes a factor after the absorption current drops to a negligible value.
This current should remain steady for the remainder of the test.
The relationship between all these currents is shown in Figure 5-59.
Figure 5-59: Current Relationships
As the asset accumulates dirt and as the insulation ages and cracks, the PI and DA ratios
decrease. Dirt accumulates based on the operation and environment of the asset. The
insulation cracks as a function of heat and aging of the asset.
Because of the effects of each of these varying currents, the resistance to ground measured
by any insulation tester varies with the amount of time the voltage is applied to the
insulation. In order to trend or compare insulation RTG values, the charge time for all tests
MUST be the same. If the charge time is not the same, the trend or comparison may not be
valid.
Finally, the charging developed by these three different currents does not dissipate
immediately when the voltage is removed at the end of the test. The insulation system
must be allowed to discharge sufficiently between resistance to ground tests in order to
obtain accurate results. A rule of thumb states that insulation takes four times the amount
of charge time to discharge.
Why Is This Important?
Resistance-to-ground readings involve three different current components: capacitive,
absorption, and leakage. The PI test allows the charging and absorption currents to decay
so that only actual leakage current is measured. As a voltage is continuously applied,
healthy insulation slowly polarizes and the absorption current diminishes. This causes a
steady rise in resistance until the majority of the current is from the small amount leaking
to ground. In poor insulation, leakage current is high enough to overshadow the lowering
absorption current and provide little increase in the resistance over time.
In Managing Motors, Richard Nailen, P.E., offers the following guidelines for interpreting
PI and DA ratios. If the PI ratio is less than 2 or the DA ratio is less than 1.5, look for
insulation degradation.
Unacceptable Acceptable
PI 1 to 1.5 2 to 4
DA 1.25 >1.50
IEEE recommends the following values for PI. Machines rated at 10,000 kVA and less
should have values at least as large as the acceptable values listed below before operation
or hi-pot testing.
PI
Class A 1.5
Class B, F, H 2.0
Data Interpretation
Because the PI and DA values are ratios, temperature correction is unnecessary. PI and
DA can be used for both on-the-spot, one-time checks and for trending over time.
Individual readings can be compared to the recommended setpoints.
A good PI Profile (PIP) shows a sharp rise followed by a steady, but slowly increasing
trend. A downward trend suggests deteriorating conditions. A flat or ragged trace
indicates short-term current transients. Such traces indicate insulation breakdown,
possibly due to contamination or moisture in the power circuit or asset. Observing the
readings over time permits scheduling of cleaning or reconditioning before failure occurs.
If the PI or DA ratio is low, isolate the problem to the circuit or the asset. Assuming the
first test was made at the MCC, run another test from the MCC with the T leads
disconnected.
If the low value is gone, the problem is in the power circuit. If the low value still exists,
test the asset at the asset connection box with the leads to the MCC disconnected. If the
low value is gone, the problem is in the cables between the asset and the MCC. If the low
value still exists, the problem is in the asset.
Examine the cables in the asset connection box. They could require cleaning, drying, or
replacement. Also, check for water in the conduit.
If the PI or DA ratio is < 1.0, look for a ground fault. Clear this fault before starting the
asset.
Some exceptions to be aware of include:
Moisture or contamination on the windings decreases the PI
The PI can be lowered by certain semiconducting materials which are used for
corona elimination on the end windings of some high-potential AC machines
Performing PI testing in ambient temperatures less than the dew point may
significantly impact the PI values
Examples
The following pictures show the response of the insulation in both a good (Figure 5-60)
and a bad (Figure 5-61) asset, with a constant voltage applied for a 10 minute period. The
increase in the RTG value is due to the decrease in current through the insulation.
Figure 5-60: Asset with a Good PI

Figure 5-61: Asset With a Bad PI
The unstable RTG readings in the bad PI are a result of low level discharges occurring in
faults in the insulation.
ROTOR INFLUENCE CHECK (RIC)
What Does It Tell You?
The Rotor Influence Check (RIC) is a graphical representation of the rotor/stator
relationship. By analyzing variations in the magnetic flux while rotating the rotor,
eccentricity and rotor defects are identified. The RIC can also be used to confirm stator
faults. Figure 5-62 shows a RIC graph for a motor with no defects.
Figure 5-62: RIC from a Good Asset
A motor acts similar to an electromagnet. The rotor acts like the core and the stator acts
like the windings of the electromagnet. A RIC shows how the rotors residual magnetism
influences the stator inductance in different positions. As the magnetic field of the rotor
interacts with more of the coils in each stator winding, the inductance of that winding
changes. This influence causes repeatable patterns of change in the graph of the stator
inductance, shown above as sinusoidal waveforms.
Broken rotor bars can cause extreme heat and vibration, which can result in winding
failure, bearing failure, and loss of torque in a motor. Eccentricity, a non-uniformity of the
air gap between the rotor and stator, can cause excessive vibration, which can result in
winding and bearing failure.
Rotor Position And Aliasing
Each RIC consists of a series of inductance measurements taken at predetermined
positions of the rotor. The amount by which the rotor is moved for each measurement and
the total rotation of the rotor for the test are determined by the number of poles in the
asset. The increment and total rotation are calculated to show the RIC pattern for one
complete pole group. If additional readings are taken beyond the total and at the same
increments, the pattern should repeat itself. Table 5-12 shows the recommended
increments and total rotation to cover one pole face for a asset with a given number of
poles.
Table 5-12: RIC Degree Increments vs. Number of Poles
The number of increments and total rotation are automatically calculated by MCEGold,
based on the entered nameplate data. You may reduce the increment and perform more
tests to cover the recommended total rotation. Increasing the increments and performing
fewer measurements than the default values is not recommended because doing this
results in aliasing. Because not enough points are taken to reveal a true picture of the
curve, aliasing produces an inaccurate and incomplete graph.
The following example shows how to determine the number of poles a asset has, the
number of total degrees to turn the rotor, and the increments by which to turn it. Start with
the basic equation:
In the formula:
F = line frequency (60 Hertz in the US)
N = synchronous asset speed
P = number of poles in the asset
120 = 120 degrees of electrical spacing between poles
For a asset whose synchronous speed is 1800 rpm, use a variation of this equation to find
the number of poles:
P = 120F/N
P = (120)x(60)/1800
P = 4 poles
Poles Increment Total
2 10.0 180
4 5.0 90
6 3.3 60
8+ 2.5 45
F
NP
120
-------- - =
Next, determine the number of degrees per pole face. To find this, divide 360 by the
number of poles.
360/4 = 90 degrees per pole face.
Next, determine the increments, in degrees, by which to position the rotor to generate an
accurate RIC pattern. To find this, divide the number of degrees per pole face by 18.
90/18 = 5 degrees.
Thus, the following would apply for a asset whose synchronous speed is 1800 rpm:
4 poles
90 degrees per pole face
5 degree increments per rotation to develop an accurate RIC
The increments were chosen since the RIC pattern typically repeats itself by the same
number of poles in the asset through a complete 360 rotation of the rotor. Using these
increments is recommended to increase consistency and reduce aliasing. Also, use the
same increments and total rotation each time you perform a RIC. This ensures that the RIC
is started and run the same way for each test. Doing this enables you to reliably compare
the data and graph to subsequent tests for trending.
When the RIC is started, the MCE measures the resistance of each phase winding. At each
increment the inductance of each winding pair is measured and recorded. Between
measurements you are prompted to move the rotor to the next position.
Data Interpretation
Aliasing
Aliasing occurs when too few measurements are taken too far apart to show the true shape
of the curve. The following figures show RICs which exhibit aliasing.
Figure 5-63 shows two waveforms of a good rotor in a 6-pole asset. The waveform with
the connected circles was generated with measurements taken at the recommended
interval of 3.3. The waveform with the dashed lines was generated with measurements
taken at 15 intervals. The waveform from measurements taken at 15 intervals shows a
lack of definition.
Figure 5-63: Aliasing
Figure 5-64 shows two waveforms taken on a asset which has known rotor faults. The
presence of the fault is hidden when the measurements are taken at 15 increments
(dashed waveform). When they were made at the recommended 3.3 increments (circles),
the presence of the rotor fault is indicated by the flattened peaks. Note that the dashed
waveforms shown in Figure 5-63 and 5-64 appear identical masking the true rotor
conditions..
Figure 5-64: Aliasing
Good Asset
Figure 5-65 shows a RIC test for a typical AC induction asset with a good rotor. The three
graphs resemble sine waves which are 120 out of phase with each other. The sinusoidal
pattern is smooth and repeatable. The amplitude of the sine waves varies from asset to
asset, due to factors specific to each asset, such as winding configuration, air gap, core
steel quality, and rotor construction and design.
Figure 5-65: RIC from Good Asset
In some assets, the amplitude changes of the graphs are very small and may appear erratic.
This erratic appearance may be due to measurement resolution steps, and not due to actual
changes in inductance. This condition may indicate a low influence rotor with no rotor
defects. One such low influence rotor is shown in the RIC graph in Figure 5-66.
.
Figure 5-66: RIC from Asset with Low Influence Rotor
Eccentricity
Eccentricity is defined as the condition of the air gap between the rotor and stator, all the
way around 360 of the asset. This gap should be the same width all the way around. If the
rotor is bowed, the bearing clearances improperly set, or the end bell not aligned properly,
the air gap will not be equal. An unequal air gap produces a phase-to-phase inductance
graph that is markedly higher at one end of the graph than at the other. This is shown in
Figure 5-67.
Figure 5-67: RIC from Asset with Eccentricity
If an eccentricity problem is suspected, continue performing the RIC to include at least
two pole faces beyond the default increment setting. An exception to be aware of is when
sleeve bearings are used in the asset. Due to their oil film, they can falsely indicate
eccentricity problems since the rotor settles when the asset is not running.
Broken Rotor Bars
A rotor with broken bars produces graphs with anomalies in their wave shapes, such as
flattened and staggered peaks.
0.686
0.688
0.690
0.692
0.694
0.696
0.698
0
1
0
2
0
3
0
4
0
5
0
6
0
mH Ph 1-2
mH Ph 1-3
mH Ph 2-3
12.500
13.000
13.500
14.000
14.500
15.000
0
1
5
3
0
4
5
6
0
7
5
9
0
1
0
5
1
2
0
1
3
5
1
5
0
1
6
5
1
8
0
1
9
5
2
1
0
mHPh1-2
mHPh1-3
mHPh2-3
Figure 5-68 shows a motor with ten broken rotor bars. These were found following a RIC.
The flattening of the peaks in the phase-to-phase inductance graphs results from the
influence of the broken bars. The irregularities in these traces are repeatable in each phase.
Figure 5-68: RIC from Motor with Broken Rotor Bars
Figure 5-69 shows a motor with cracked welded joints at the shorting rings. The cracked
welded joints were found in 14 out of 122 rotor bars after a RIC was taken. The erratic
pattern of flattened and staggered peaks points to the presence of the broken bars.
Figure 5-70 shows the RIC test of a 480 volt 60 HP AC induction motor with broken rotor
bars and a slight air gap problem. Note the flattened peaks in each phase-to-phase graph.
Figure 5-71 shows the staggered peaks in a RIC for a 480 volt 5 HP motor. A rotor
anomaly was determined to be the cause for these peaks. This was the result of a
maintenance supervisor drilling a hole in one rotor bar as a demonstration.
One-Up/Two-Down and Two-Up/One-Down
Phase-to-phase or turn-to-turn stator winding shorts can result in either a one-up/two-
down or two-up/one-down RIC pattern. This is shown in the graphs in Figure 5-72.
Figure 5-72: RIC from Motor with Phase-to-Phase or Turn-to-Turn Shorts
To assist in the analysis, compare the RIC with the phase-to-phase resistance readings on
the standard test. If the same phases are affected resistively and inductively, this further
confirms a winding defect. If resistance readings do not confirm this condition, evaluate
the asset for eccentricity/air gap problems.
DC Bar-to-Bar Test
What Does It Tell You?
Testing the resistance between commutator bars gives an indication of the comparative
value of resistance that exists between all like electrical circuits in an armature.
The commutator consists of insulated segments assembled into a cylinder and held
together by insulated rings. Electric current is transferred to the armature windings by
brushes made mainly of carbon and graphite. Brush wear creates carbon dust, a
conductive contaminant, which penetrates into crevices, cracks and openings of the
armature. Copper particles add to the contaminant accumulation when the wrong brushes
are installed or the brushes are improperly installed, or when maintenance is inadequate. If
the insulating material on the commutator bars or their risers has cracked, these
contaminants can short entire windings.
Also, high resistance connections can develop at the risers causing open or high-resistance
armature coils. Equalizing connections can break and cause an imbalance due to the loss
of equalization.
Data Interpretation
The resistance readings between bars are in the microhm range for medium to large
machines. Most DC assets of this size have armatures constructed with equalizing jumpers
or compensating shorting connections. The effect of these connections on the Bar-to-Bar
test results shows as a regular pattern of change from bar to bar. Good bars have 1 or 2
different values. If a bar differs greatly from either of these 2 values then look for faults.
Armatures with 50% compensation have every other bar equalized; with 33%
compensation have every 3rd bar equalized; with 25% compensation have every 4th bar
equalized.
MCE ANALYSIS
AC Induction Assets
Normal - smooth three-phase sinusoidal waveforms
Rotor Defect - repeatable erratic inductance throughout the peaks of the
waveforms
Eccentricity - inconsistent variations in the amplitude of the waveforms. Static
eccentricity sometimes causes a consistent separation in the three sine waves,
coupled with a low inductive imbalance.
One method of analyzing a RIC is done by following four steps, outlined by the acronym
SAME.
S - look at the scale; verify correct resolution
A - check the alignment of the peaks; check for eccentricity
M - check the max-to-min values of the peaks; all three waveforms should be the
same; check for stator problems
E - evaluate the characteristics of the waveforms
Standard Test
In the Fault Zone Report, check for Caution and Alarm indications. Click the
value highlighted in yellow or red to see the recommended actions.
Low Resistance-to-Ground - RTG in Caution or Alarm indicates a possible
breakdown in the insulation system.
High Capacitance-to-Ground - CTG in Caution or Alarm indicates an increase in
the contamination on the surface of the insulation.
High Resistive Imbalance - Resistive Imbalance in Caution or Alarm indicates
high resistance connection in the switchgear, disconnect, or asset connection box.
Refer to the individual phase-to-phase resistance readings to assist in locating the
fault.
High Inductive Imbalance - Inductive Imbalance in Caution or Alarm indicates a
winding defect (turn-to-turn or phase-to-phase) or severe eccentricity. Refer to
the individual phase-to-phase inductance readings to assist in locating the fault. If
a RIC has not been performed, perform a RIC to obtain additional information.
Polarization Index/Dielectric Absorption
Low PI or DA ratio - PI or DA in Caution or Alarm indicates changing or
excessive surface contamination.
Breakdown of insulation system.
At this point, a Condition Code may be assigned and Notes completed to explain the
following:
Asset condition/status; basis for the asset condition assigned.
Anomalies that had to be overcome during the performance of the test.
If multiple tests were performed during troubleshooting, explain where test leads
were connected for each test.
AC Synchronous Assets
Stator
Rotor Defect - appears like a normal sine wave but has a larger than normal
inductive imbalance
eccentricity can sometimes cause a consistent separation in the three sine waves.
SAME.
Standard Test
fault.
winding defect (turn-to-turn or phase-to-phase), circuit defect (cable short or
power factor correction capacitor failure), or severe eccentricity. Refer to the
individual phase-to-phase inductance readings to assist in locating the fault. If a
RIC has not been performed, perform a RIC to obtain additional information on
the rotor condition.
Low PI or DA ratio- PI or DA ratio in Caution or Alarm indicates changing or
Step Voltage
If the plot of the curve of current versus voltage deviates from near linear,
impending breakdown is suggested.
Field Circuit
Synchronous Test
Low Resistance-to-Ground - RTG in Caution or Alarm indicates a breakdown in
the insulation system.
High/Low Resistance - Resistance in Caution or Alarm indicates a high or low
resistance of the field windings.
NOTE: The Caution and Alarm limits are set based on nameplate field voltage
and current values at normal operating temperature of the asset. Testing on a cold
asset may indicate values outside the Caution and Alarm settings.
Low Inductance - Low Inductance in Caution or Alarm indicates turn-to-turn
faults in the field coils.
Low PI or DA ratio - PI or DA ratio in Caution or Alarm indicates changing or
following:
Step Voltage
AC Wound Rotor Assets
Stator
Rotor Defect - appears like a normal sine wave but has a larger than normal
inductive imbalance
eccentricity can sometimes cause a consistent separation in the three sine waves,
coupled with a low inductive imbalance.
SAME.
Standard Test
fault.
winding defect (turn-to-turn or phase-to-phase) or severe eccentricity. Refer to
the individual phase-to-phase inductance readings to assist in locating the fault. If
a RIC has not been performed, perform a RIC to obtain additional information.
Step Voltage
Rotor
Standard Test
value highlighted in yellow or red for recommended actions.
high resistance connection on the slip ring or winding connections. Refer to the
individual phase-to-phase resistance readings to assist in locating the fault.
winding defect (turn-to-turn or phase-to-phase). Refer to the individual phase-to-
phase inductance readings to assist in locating the fault.
Step Voltage
Resistor Bank
Resistor Bank
high resistance connection between the resistors or a faulty resistor. Refer to the
individual phase-to-phase resistance readings to assist in locating the fault.
following:
Step Voltage
DC Assets
Armature Circuit
Standard Test
High/Low Resistance - values in Caution or Alarm indicate high resistance
connection in the switchgear, disconnect, or asset connection box. This can also
indicate improper brush wear/seating or a poor commutator film.
High/Low Inductance - values in Caution or Alarm indicate a winding defect
(turn-to-turn or coil-to-coil).
Bar-to-Bar
High/Low Resistance - values significantly above or below the average
resistance reading indicate an open or a short in the armature winding or
commutator segments.
Field Circuit
Standard Test
High/Low Resistance - values in Caution or Alarm indicate a high resistance
connection in the switchgear, disconnect, or asset connection box.
High/Low Inductance - values in Caution or Alarm indicate a winding defect
(turn-to-turn or coil-to-coil).
Low PI or DA Ratio - PI or DA Ratio in Caution or Alarm indicates changing or
following:

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REV. 0-04/08 2008 PdMA Corporation 5-1

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